Waste Minimization and Cleaner Production

7/31/2019 Waste Minimization and Cleaner Production

1/75

Waste Minimization and

Cleaner Production


2/75

Introduction In the last 15 20 years there has been a growing world

wide movement among government and industry to changethe way industry interacts with the environment.

The focus of this movement has been to reduceenvironmental impacts from industry through changes inindustrial behavior and technology.

All of them are based on what is commonly known as theprecautionary Principle, also known by the old saying,

An ounce of prevention is worth a pound of cure.

It is better, and usually much less expensive, to preventenvironmental problems from happening than to fix themonce they are created.

And if we dont know what effects our actions will have onthe environment, we should proceed with caution and try tominimize any potential effects that might occur.


3/75

Objective

The objective of this lecture is to briefly define the mostcommon concepts used for industrial environmentalmanagement and to show their relationships.

There are many actions industry can take, from the

small to the very large, along a path orstaircase thatleads to increasingly broad impacts on and interactionswith the environment and society.

No industry, and no society, is really at the top of thestaircase; the top, which is sustainable development, is,like quality, a goal which is always elusive and for whichwe should never stop striving.


4/75

The Staircase of Concepts In IndustrialEnvironmental Management


5/75

Concept of Stair Case

There are three types of concepts on the staircase.

(1)Macro-scale concepts:

The macro-scale concepts ofsustainable development and industrialecology extend far beyond the firm and include relationships betweencompanies, social institutions, the public and the environment in all its facets.

(2) Firm-wide concepts:

The firm-wide concepts of environmental management systems and cleanerproductionaddress all aspects of the firms operations, from use of naturalresources to suppliers to production to product use to product disposal.

(3) Operational concepts:

The remaining operational concepts address specific functions of the

business.


6/75

Macro-Scale Concepts


7/75

Sustainable Development

Sustainable development is the development that meets the

needs of the present without compromising the ability of futuregenerations to meet their own needs

It contains within it two key concepts:

The concept of "needs", in particular the essential needs of the world's poor, towhich overriding priority should be given; and

The idea oflimitations imposed by the state of technology and social organizationon the environment's ability to meet present and future needs.

Thus the goals ofeconomic and social development must be defined in terms ofsustainability in all countries -- developed or developing, market-oriented or centrally

planned.

Interpretations will vary, but must share certain general features and must flow from a

consensus on the basic concept of sustainable development and on a broadstrategic framework for achieving it.


8/75


9/75


10/75


11/75


12/75


13/75


14/75

Industrial Ecology

Industrial ecology is the means by which humanity candeliberately and rationally approach and maintain adesirable carrying capacity, given continued economic,cultural and technological evolution.

The concept requires that an industrial system be viewednot in isolation from its surrounding systems, but in concertwith them.

It is a system view in which one seeks to optimize the totalmaterials cycle from virgin material, to finished material, toproduct, to waste product, and to ultimate disposal.

Factors to be optimized include resources, energy and

capital


15/75

Aim of Industrial Ecology

The aim of industrial ecology is to interpret andadapt an understanding of the natural systemand apply it to the design of the man-madesystem, in order to achieve a pattern ofindustrialization that is not only more efficient,but that is intrinsically adjusted to the tolerancesand characteristics of the natural system.

The emphasis is on forms of technology that workwithnatural systems, not againstthem...


16/75


17/75


18/75


19/75


20/75


21/75


22/75


23/75


24/75

Firm-Wide Concepts

These are concepts that affect the whole scope of the business enterprise, not just

parts of it.

They are essentially management philosophies and practices rather than technical

practices and as such are best directed to the top levels of management.


25/75

Cleaner Production

Cleaner production means the continuous application of an integratedpreventive environmental strategy to processes and products to reduce risks

to humans and the environment.

For production processes, cleaner production includes conserving raw materials

and energy, eliminating toxic raw materials, and reducing the quantity and toxicity of

all emissions and wastes before they leave a process.

For products, the strategy focuses on reducing impacts along the entire life cycleof the product, from raw material extraction to the ultimate disposal of the product.

Cleaner production is achieved by applying know-how, by improving technology,

and by changing attitudes.

The conceptual and procedural approach to production that demands that all

phases of the life-cycle of products must be addressed with the objective of the

prevention or minimization of short and long-term risks to humans and the

environment.


26/75


27/75

Pollution Prevention

The USA Pollution Prevention Act of 1990 defines pollution prevention as a

goal which is realized through source reduction.

The term ''source reduction'' [or pollution prevention] means any practicewhich

Reduces the amount of any hazardous substance, pollutant, orcontaminant entering any waste stream or otherwise released into the

environment (including fugitive emissions) prior to recycling, treatment,or disposal

Reduce the hazards to public health and the environment associated withthe release of such substances, pollutants, or contaminants

The term includes equipment or technology modifications, process orprocedure modifications, reformulation or redesign of products,substitution of raw materials, and improvements in housekeeping,maintenance, training, or inventory control.


28/75

Operational Concepts


29/75

Why Waste Minimization ?

The generation of large volumes of waste correlates with

the depletion of mostly non-renewable resources

The energy requirement for the transformation and

upgrading of wastes is in proportion to the quantities treated

and rises exponentially with increasing dilution of the waste

The increasing total costs for collection, segregation,

intermediate storage, transport etc.

Increased public and legislative pressures seem likely to do

mitigated only by waste reduction/minimization

Since waste equals inefficiency, reducing waste increases

efficiency and hence profitability


30/75

Waste Minimization

Waste Minimization (WM) is the reduction, to the extent feasible, of hazardous

waste that is generated or subsequently treated, sorted or disposed.

It includes any source reduction or recycling activity undertaken by a generator

that results in either

(1) The reduction of total volume or quantity of hazardous waste, or

(2) The reduction of toxicity of hazardous waste, or both, so long as such

reduction is consistent with the goal of minimizing recent and future threats to

human health and the environment.


31/75


32/75

Clean Technology

It has two ideas

1. The emphasis is on the generation of less waste and onthe consumption of fewer raw materials and less energy.Thus a simple but satisfactory definition of cleantechnology is any technology or process which uses

fewer raw materials and/or less energy, and/or generatesless waste than an exiting technology or processes.

2. The avoidance of end-of-pipe emission reduction is alsoemphasized. End-of-pipe methods are those that attemptsto reduce the environmental impact of a waste, after thatwaste has been produced.

Th t f i i h b


33/75

The concept of zero emission processes has beenespoused, such a target is thermodynamically impossiblefor a manufacturing processes, if such processes isregarded as an open system (a system that exchangesboth material and energy with its surroundings).

Manipulating the system boundary in an attempt toproduce a closed system (One that exchanges only

energy and not materials with its surroundings) isanalogous to the end-of-pipe solutions to materialproblems, which merely transfers matter from onemedium to the other.

Enlarging the systems boundary to incorporate theenergy supply facility reveals that the enlarged system isin fact, open and depositing material into thesurrounding.


34/75


35/75

What is life cycle assessment ?

It is a systematic inventory and comprehensive assessment of environmental effectsof two or more alternative activities involving a defined product in a defined space

and time including all steps and co-products in its life cycle.

Any product may have following stages in its life cycle

Raw materials acquisition

Bulk material processing

Engineered and specialty material production

Manufacturing and assembly

use and service

Retirement Disposal


36/75

Product life cycle system (from Koelein and Menerey, 1993)


37/75

Steps Necessary to conduct a Life Cycle Assessment

An LCA has the following phases:

Planning Screening

Data collection (inventory) Data treatment (aggregation/classification) Evaluation


38/75


39/75

(material down scaling into another product system)


40/75


41/75


42/75


43/75


44/75


45/75


46/75

West Reproduction Technique


47/75

Thermodynamics and Material Flows in the Economy


48/75

Transformationprocess

Material inputs

Energy inputs

Wastes & emissions

Useful outputs

Thermodynamics and Material Flows in the Economy

1. Law of Thermodynamics:Conservation of energy

In non-nuclear processes energy can neither be created nor destroyed. Energy can onlybe transformed from one form into another. The total amount of energy input to a non-

nuclear transformation process is thus equal to the total amount of energy output.

Conservation of massThe total mass of material inputs into a (non-nuclear) material transformation process is

equal to the total mass of material outputs.

Conservation of mass per chemical elementThe total mass of each chemical element is conserved during every (non-nuclear)

material transformation process.

The material transformation process


49/75

afterbefore

outputinput

emissionswastesproductsancillarydirect

EntropyEntropy

EnergyEnergy

MassMassMassMassMass

Direct materials

Ancillary materials

Low-entropy energy

Economic output

Wastes & emissions

High-entropy energy

Transformation process

1. Law of TD

2. Law of TD

e ate a t a s o at o p ocess

Solar Radiation Earths RadiationMaterial Flows in the Economy


50/75

Ecosphere

Anthroposphere

Materials

Sink for:

Wastes

&Emissions

Needs & Wants

(Teff~ 6000K

mainly UV, optical and IR)(Teff~ 300K

mainly IR)

Services

Products

Production

All materials that enter the economic system will eventually leave it

Large amounts of low-entropy energy are needed to drive the economic system

All economic activity is essentially dissipative in both materials and/or energy

Low-entropyEnergy

Material Flows in the Economy

high-entropy

Energy

Material Flow Analysis (MFA)


51/75

Accounting methodology for material stocks:

Producing

processes

Imports Exports

Consuming

processes

Stocks of

upstream

materials

Stocks of

downstream

materials

Stocks outside

of boundaries

Stocks outside

of boundaries

Material

stock

Transformation processes

Transportation processes

lllll

tt

ExportImportnConsumptioProductionStock

tdExportImportnConsumptioProductionStockdStock

Methodology Single material or substance

MFA Methodology Single material or substance


52/75

Material

production

Potential

Waste

Component

fabrication

Product

Assembly

Product

Use

Raw

Material

Material Components Products

Imports / Exports

Domestic Environment

Extraction ReleaseRecycling Reuse

Example: Copper Flows in North America in 1994 (in kt / y)


53/75

Import / Export

EnvironmentLithosphere

Production:

Mill, Smelter,

Refinery

Fabrication &

Manufacturing

Use Waste

Management

Concentrate,

Blister, Cathode

325

Ingots

3

Semis,

Finished Products

17

Stock

Cathode

3270Prod. Cu

2640

Prod. Alloy

690

Stock

1920

Discards

1410

Old

Scrap

190

New Scrap

730140

Old Scrap180330

Tailings & Slag 365

Ore

3130

Landfilled Waste,

Dissipated

Source: CIE, Yale

710

3

Recycling


54/75

Recycling

There are almost always some wastes created by production processes, so they

need to be recycled as much as possible. Recycling can be broken down into

closed-loop recycling (which is really just a production process extension rather

than recycling), on-site recycling and re-use, off-site recycling, and reclamation.

Common Effluent Treatment Plants


55/75

Leachate collection and ewaporation pond

at the common facility for waste

management at Hyderabad (A.P.)

Common Effluent Treatment Plants

Oxidation Pond based Treatment Plant

at Vrindavan, UP

Pollution Control


56/75

Pollution Control

Pollution control systems to reduce waste volume or toxicity are a necessityto manage wastes that cannot be prevented or exchanged. The relationship

to the higher concepts is one of fast resort

Waste Disposal

A view of hazardous waste storage pits


57/75

Indian Scenario

Hazardous Wests Generating Units &


58/75

g

HW Generation Scenario

HW generation in States - No uniform trend No. of Units generating Hazardous Wastes gone-

up

Factors responsible:

Changes in regulatory classification:o Change over from 18 waste categories with

annual threshold limits to 36 processes and

corresponding waste streams

o Emphasis on waste minimization-zerodischarge(Tanneries,textiles)

o Fly-ash,gypsum sludge excluded

o Units closed/New Units

Waste Stream wise Quantification of Hazardous Wastes


59/75

Product Waste Stream WGF (kg/tonne of product)

Ethylene/Propylene Spent caustic from CausticTower

0.06

Oil Soaked Carbonaceous Coke 0.017

Spent Palladium Catalyst 0.007

Butadiene Butadiene Polymer Waste 0.06

Solvent regeneration residue 0.4

Benzene Spent Nickel Catalyst 0.03

Spent Nickel-MolybdenumCatalyst

0.003

Spent Cobalt-MolybdenumCatalyst 0.007

Waste Stream wise Quantification of Hazardous Wastes


60/75

Product Waste Stream WGF (kg/tonne of product)

Xylene Spent clay 0.50

Vinyl ChlorideMonomer

Carbon Waste 0.02

EDC Bottom Viscous 4.0

Reactor Waste 0.014

Polyvinyl Chloride PVC Wet resin 4.0

Ethylene Oxide/Ethylene Glycol

Spent Silver catalyst 0.08

Polythylene Polymeric waste 0.02

Extruder waste 2.4

Maleic anhydride Distillation bottoms 60

ETP sludge 0.4

Waste Stream Contd. ..


61/75

Product Waste Stream WGF (kg/tonne ofproduct)

Phthalic Anhydride Vanadium pentoxide catalyst 167

Purge cut 24

Tar residue 12

Dimethyl Terephthalate Crude ester distillation residue 54

Linear Alkyl Benzene Calcium fluoride sludge 6.0

Spent alumina 0.32Spent catalyst 0.04

Spent molecular sieve 0.35

Spent carbon 0.02

Oil soaked sand 0.8

Isopropyl Alcohol Spent copper catalyst 45.0

Acetone Distillation by product (Tarry waste) 8.0

Petrochemical Industry : Suggested Waste Recycling Options


62/75

Product Waste Recycling Measures

Ethylene/ Propylene Polymeric waste Refining and reuse

Benzene Spent nickel catalyst Metal recovery

Spent nickel-molybdenumcatalyst

Metal recovery

Spent cobalt-molybdenum

catalyst

Metal recovery

Polyvinyl chloride PVC wet resin Reuse for manufacturinguseful items

Isopropyl alcohol Spent copper catalyst Recovery of acid

Acetone/Phenol Solvent waste Use as a fuel in the boiler

Polypropylene Powder waste Melting, extrusion andconversion to low-gradearticles

Cumene Cumene catalyst Acid recovery

Cumene bottoms Use as a fuel


63/75

HW Generating Industries & HW Generation

C ti Fi


64/75

S.No. State No. ofIndustriesas per HWM

Rules, 1989

Total HWgeneration inTPA

HW generatingIndustries(No.s) as per

HWM Rules,2000/2003

Total HWgenerationin TPA

1. AP 501 1,11,098 1532 507046

2. Assam 18 1,66,008 23 4,000

3. Bihar 42 26,575 31 Not given

4. Chandigarh 47 305 271 8,4255. Delhi 403 1,000 1777 17,000

6 Goa 25 6,598 49 Not Provided

7. Gujarat 2984 4,30,030 6052 12, 07,000

8. Haryana 309 31,046 889 14,972

9. Himachal 116 2159 575 Not given10. Karnataka 454 1,03,243 1589 92,013

11. Kerala 133 1,54,722 423 83,530

12. Maharashtra 3953 20, 07,846 4571 14,07,480

13. MP 183 1,98,669 753 Not given

14. Orissa 163 3,41,144 257 74,918

Comparative Figures

HW Generating Industries & HW Generation

C ti Fi


65/75

S.

No.

Name of theState

No. ofIndustries asper HWM

Rules, 1989

Total HWgeneration inTPA

No. of HWIndustries asper HWM

Rules,2000/2003

Total HWgenerationin TPA

16. Pondicherry 15 8,893 66 30,320

17. Punjab 700 22,709 1448 15,769

18. Rajasthan 332 1,22,307 512 1,83,737

19. Tamilnadu 11003,94,208

2177 1,81, 624

20. Uttarpradesh 1036 1,45,786 1633 82,375

21. West Bengal 440 1,29,826 568 Not given

22 Chattisgarh - - 149 Not given

23. Mizoram - - Nil Nil

24. Meghalaya - - 39 37, 41225. Nagaland - - 03 448

26. Daman, Diu &DNH

- - 598 Not given

27. Jharkhand - - 169 Not given

28. Uttaranchal - - 137 Not given

29. Manipur - - Nil -

Comparative Figures

STATE-WISE COMPARATIVE HW GENERATING UNITS AS


66/75

PER HWM RULES, 1989 & 2003

309

47

116133

183 163

57

271

889

575

423

753

257207

0

100

200

300

400

500

600

700

800

900

1000

Chandigarh

Haryana

Hima

chal

Ke

rala

MP

Or

issa

J

&K

STATE

No.

ofHWg

eneratingUn

its

HW generating Units as per HWM RULES, 1989

HW generating Units as per HWM RULES, 2003

Comparative HW generating Units as


67/75

501

1532

2984

6052

454

1589

3953

4571

700

1448

1100

2177

1036

1633

0

1000

2000

3000

4000

5000

6000

7000

AP

Gujarat

Karnataka

Mahara

shtra

P

unjab

TN

UP

State

perHWM Rules, 1989 and 2003

No. of HW units as per HWM Rules, 1989

No. of HW units as per 2003

HWs - Landfillable, Recyclable,


68/75

650

410

147

230

264

126

626

628

154

56 109

0

200

400

600

800

1000

1200

1400

1600

Guja

rat

AP

Ma

haras

htr

Oris

sa

State

Incinerable as per HWM Rules, 2003

Landfillable Recyclable Incinerable


69/75

S No State Total HW No of TSDF in No of sites No of sites

Status on HW Generation & TSDF in Operation in Major States


70/75

S.No.

State Total HW

generation in

000 TPA

No. of TSDF inoperation/underconstruction

No. of sites

notified

No. of sites

identified

1. AP 507 01 02 02

2. Assam 4 - - -3. Chandigarh 8 - - -

4. Delhi 17 Nil Nil 03

6 Goa - Nil Nil Nil

7. Gujarat 1207 07 16 22

8. Haryana 15 - 01 01

9. Himachal - - 02

10. Karnataka 92 Nil 02 02

11. Kerala 84 Nil 01 01

12. Maharashtra 1407 02 02 06

13. MP - Nil Nil 03

14. Orissa 75 Nil 01 0115. Pondicherry 30 Nil Nil Nil

16. Punjab 16 Nil 01 01

17. Rajasthan 184 Nil 01 08

18. Tamilnadu 182 Nil 01 03

19. Uttarpradesh 82 Nil 03 05

Common TSDFMulti State


71/75

Flexibility for Industries located on Inter

State Border

Problem facing smaller States/UTs

Incinerable wasteMin. Scale of operation

- about 1.0 ton per hour

Practical Difficulties: Delhi, Chandigarh,

Daman, Goa

Incinerable HW as per HWM Rules 2003


72/75

9.3 12.6

61.4

147 154

02040

6080

100120140160180

Orissa

AP

UP

Gujarat

Maha

rashtra

State

IncinerableHWin

'000

Tonnes

Incinerable HW as per HWM Rulex, 2003

Recycling of Hazardous Waste


73/75

Import of specified categories permitted for Recyclingusing environmentally sound technology

Recycling of hazardous waste is permitted for unitsregistered with CPCB and having ESM Facilities.

Guidance Document prepared on ESM of followingRecyclable wastes : Used Oil, Waste Oil, Non-ferrousmetals wastes

Technology Up gradation: linked to scale of operation

Large Gap between Demand and Supply w.r.t Lead ,Copper and Zinc wastes.

India favours free movement of recyclables.

Recycling of Hazardous Waste contd


74/75

Recyclable Wastes for which State of Art Facilities areneeded

Mercury Bearing wastes.

Nickel Cadmium Batteries

Spent Catalyst

E- Waste:

Guidance document under preparation covering

i ) Informal sectorii ) leaded glassiii) precious metals recovery etc.,


75/75

Documents

Waste Minimization and Cleaner Production